US11017939B2ActiveUtilityPatentIndex 62

Magnetic component assembly with filled gap

Assignee: EATON INTELLIGENT POWER LTDPriority: Mar 15, 2013Filed: Jan 3, 2014Granted: May 25, 2021

Est. expiryMar 15, 2033(~6.7 yrs left)· nominal 20-yr term from priority

Inventors:KRISHNAMOORTHY AHILA BOGERT ROBERT JAMES YAN YIPENG

H01F 27/29H01F 3/10H01F 27/292H01F 2003/106H01F 2017/048H01F 27/306H01F 17/04H01F 27/255H01F 3/14H01F 27/2847H01F 27/24

PatentIndex Score

Cited by

References

Claims

Abstract

Magnetic component assemblies for circuit boards include magnetic cores formed with a gap and preformed conductive windings sliding assembled to the cores via the gaps. The gaps in the cores are filled with a magnetic material to enhance the magnetic performance. The magnetic component assemblies may define power inductors.

Claims

exact text as granted — not AI-modified

What is claimed is:

1. A surface mount magnetic component assembly consisting of:
a magnetic core consisting of only one core piece fabricated from a first magnetic material into a body having opposed top and bottom walls and opposed first and second walls extending between the top and bottom walls, the magnetic core having at least one gap formed therein and extending only partially between the opposed first and second walls;
a conductive winding extending through the at least one gap; and
a second magnetic material, separately provided from the magnetic core, filling the at least one gap and cured in place.

2. The surface mount magnetic component assembly of claim 1 , wherein the first magnetic material is a ferrite material and the second magnetic material is a non-ferrite material.

3. The surface mount magnetic component assembly of claim 2 , wherein the ferrite material is ferrite particles mixed with a polymer to form a distributed gap material.

4. The surface mount magnetic component assembly of claim 2 , wherein the second magnetic material is metal particles mixed with a polymer to form a distributed gap material.

5. The surface mount magnetic component assembly of claim 1 , wherein the conductive winding is a preformed winding.

6. The surface mount magnetic component assembly of claim 1 , wherein the magnetic core includes opposing lateral side walls and opposing longitudinal side walls, and wherein the gap extends only partially between the opposing lateral side walls.

7. The surface mount magnetic component assembly of claim 1 , wherein the magnetic core further includes opposing lateral side walls and opposing longitudinal side walls, and wherein the gap extends only partially between the longitudinal side walls.

8. The surface mount magnetic component assembly of claim 1 , wherein the gap extends parallel to the top side wall.

9. The surface mount magnetic component assembly of claim 1 , wherein the gap extends perpendicularly to the top side wall.

10. The surface mount magnetic component assembly of claim 1 , wherein the gap is open to the bottom side wall.

11. The surface mount magnetic component assembly of claim 1 , wherein the only one core piece has a U-shaped cross section.

12. The surface mount magnetic component assembly of claim 6 , wherein the only one core piece has a T-shaped cross section.

13. The surface mount magnetic component assembly of claim 1 , wherein the conductive winding is preformed and separately provided from the magnetic core.

14. The surface mount magnetic component assembly of claim 1 , wherein the conductive winding has a main winding section, terminal sections extending perpendicularly to the main winding section, and surface mount terminal sections extending parallel to the main winding section.

15. The surface mount magnetic component assembly of claim 14 , wherein the gap has a thickness, the gap thickness being greater than a thickness of the main winding section to accommodate a slidable insertion of the main winding section into the gap.

16. The surface mount magnetic component assembly of claim 14 , wherein the gap has a width, and at least one of the surface mount terminal sections has a width greater than the gap width.

17. The surface mount magnetic component assembly of claim 1 , wherein the assembly defines a power inductor.

18. A surface mount magnetic component assembly consisting of:
only one preformed magnetic core piece fabricated from first magnetic powder particles mixed with a polymer, the only one core piece having a gap formed therein;
a conductive winding defined by a main winding section and surface mount terminal sections, the main winding section extending through the gap; and
a second magnetic material filling the gap, the second magnetic material separately provided from the only one preformed magnetic core piece and fabricated from second magnetic powder particles mixed with a polymer that is cured in place adjacent the winding in the gap;
wherein the first magnetic materials are ferrite particles and the second magnetic powder materials are non-ferrite particles.

19. The surface mount magnetic component assembly of claim 18 wherein the only one preformed magnetic core piece has a U-shape.

20. The surface mount magnetic component assembly of claim 18 wherein the only one preformed magnetic core piece has a T-shape.

21. The surface mount magnetic component assembly of claim 18 , wherein the conductive winding is preformed from the only one preformed magnetic core piece.

22. The surface mount magnetic component assembly of claim 18 , wherein the assembly defines a power inductor.

23. A surface mount magnetic component assembly consisting of:
only one preformed magnetic core piece fabricated from first magnetic powder particles mixed with a polymer, the only one preformed magnetic core piece having a gap formed therein;
a preformed conductive winding with a main winding section extending through the gap and with opposed terminal sections extending perpendicularly to the main winding section, the opposed terminal sections extending externally to the only one preformed magnetic core piece; and
a second magnetic material filling the gap, the second magnetic material separately provided from the only one preformed magnetic core and having second magnetic powder particles mixed with a polymer that is cured in place in the gap;
wherein the first and second magnetic powder particles are ferrite particles and wherein the other of the first and second magnetic powder materials are non-ferrite particles; and
wherein the assembly defines a power inductor.

24. A surface mount magnetic component assembly consisting of:
a magnetic core consisting of only one magnetic core piece fabricated from a first magnetic material, the only one magnetic core piece having opposed top and bottom walls and at least one non-magnetic gap formed therein and extending between the opposed top and bottom side walls;
a preformed conductive winding including a planar section extending through the at least one non-magnetic gap; and
a second magnetic material, separately provided from the only one magnetic core piece, applied to the non-magnetic gap and cured in place.

25. The surface mount magnetic component assembly of claim 24 , wherein the second magnetic material is applied to the non-magnetic gap in one of a liquid form, a semisolid form, or solid form.

26. The surface mount magnetic component assembly of claim 24 , wherein the second magnetic material is applied to the non-magnetic gap in one of a ribbon or tape configuration.

27. The surface mount magnetic component assembly of claim 24 , wherein at least a portion of the magnetic core has a U-shaped cross section.

28. The surface mount magnetic component assembly of claim 24 , wherein at least a portion of the single magnetic core piece has a T-shaped cross section.

29. The surface mount magnetic component assembly of claim 24 , wherein the assembly defines a power inductor.

30. The surface mount magnetic component assembly of claim 24 , wherein the magnetic core further includes opposing lateral side walls, and wherein the non-magnetic gap extends partially between the opposing lateral side walls.

31. The surface mount magnetic component assembly of claim 24 , wherein the magnetic core further includes opposing longitudinal side walls, and wherein the non-magnetic gap extends to the longitudinal side walls.

32. The surface mount magnetic component assembly of claim 24 , wherein the non-magnetic gap extends parallel to the top side wall.

33. The surface mount magnetic component assembly of claim 24 , wherein the non-magnetic gap extends perpendicularly to the top side wall.

34. The surface mount magnetic component assembly of claim 24 , wherein the non-magnetic gap is open to the bottom side wall.

35. The surface mount magnetic component assembly of claim 24 , wherein the conductive winding has a main winding section, terminal sections extending perpendicularly to the main winding section, and surface mount terminal sections extending parallel to the main winding section.

36. The surface mount magnetic component assembly of claim 35 , wherein the non-magnetic gap has a thickness, the gap thickness being greater than a thickness of the main winding section, whereby the main winding section can be slidably inserted into the non-magnetic gap.

37. The surface mount magnetic component assembly of claim 35 , wherein the non-magnetic gap has a width, and at least one of the surface mount terminal sections has a width greater than the gap width.

38. The surface mount magnetic component assembly of claim 24 , wherein the second magnetic material has different magnetic properties than the first magnetic material.

39. The surface mount magnetic component assembly of claim 24 , wherein the bottom side wall of the magnetic core is flat.

40. The surface mount magnetic component assembly of claim 24 , wherein the bottom side wall includes a projecting guide surface.

Cited by (0)

No later patents cite this yet.

References (0)

No backward citations on record.